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PRODUCTION PROCESS & QUALITY CONTROL
PROCEDURES |
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The manufacturing
of sports balls has become a specialized business
over the years as competition and quality
being at the top.
There are many quality control procedures
involved and quality control measures taken
at Trumans to manufacture high quality sports
balls. Skipping the details, only overview
is given here for the common understanding. |
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Tech
Packs Preparation & Production Order |
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The
product spec sheets are prepared of each
order by quality assurance department along
with the help of export, production
and R & D departments. The tech packs
deal comprehensively with the production
of products and serve as a vital tool
in planning, controlling and coordinating
different operation of the company.
The production order is
issued after getting order confirmation,
finalizing technical details with the customer
and tech packs preparation. |
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Material
Selection & Procurement |
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Top
priority is given on material selection
and procurement. Different variants of material
are used in ball manufacturing. Our competent
purchase department is always in search
of best available options for ball materials
The raw material is directly
purchased from the manufacturers and importers.
The material is carefully selected to ensure
uniform thickness, weight, right contents
and minimum flaws.
The purchase department
always keeps close look on latest materials
and innovations in the market to get newest
and finest material for production.
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Material
Storage |
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At
the time arrival of all kinds of material,
it goes through the quality control tests
and inspections. The material is systematically
and safely stored in the store after passing
the strict initial checking. |
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Material
Issuance |
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Material
is issued for production from store very
systematically to minimize minor mistake
which in the end become major blunders and
delayed orders in some other organizations. |
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Lamination |
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After
the issuance of material for production,
first the synthetic leather rolls are cut
in specific sizes. The fabric and synthetic
leather sheets are bonded with latex rubber
which contains anti mildew agents to prevent
the growth of mildew.
Each layer of laminated
sheets is checked for thickness and adhesiveness
to get proper weight and control of sports
balls. In some models, the neoprene air
mattress is used in this process to give
suppleness and excellent bounce control
of the ball.
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Dryness |
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The
fabric and synthetic leather laminated sheets
are kept in drying hall in specific environment
for at least 48 hours. The natural dryness
in sun or in drying hall is preferred. The
dryness and adhesiveness of laminated sheets
are again checked before cutting process. |
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Cutting |
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The
cutting of laminated sheets is performed
on cutting press with the help of cutting
dyes. Special techniques are followed in
this process to get equal thickness and
weight proportions of the individual panels.
This gives balance and uniform bounce to
the ball. The cut panels in the pentagonal,
hexagonal or rectangular shapes are stacked
and checked for size regularity.
The defective panels of balls are sorted
out. The remaining panels are bundled and
are now ready for printing.
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Printing |
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The
panels of balls are now silk screen printed
according to the designs and logos approved
by the customer. The colour mixing and matching
is very technical job and our technicians
are highly trained and experienced in this
field. The long life quality printing ink
keeps the face of ball intact for long time
after extended play.
The printed panels are
checked against defects of printing and
passed panels are bundled together with
bladder to check the weight of unstitched
ball.
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Stitching |
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The
balance of ball requires consistent pressure
of every stitch as different pressure applied
on stitches changes the shape of ball. Our
hardworking and dedicated stitching workers
sew together the different panels of balls
and give it the shape, strength and design
which customers want to see.
The strongest threads are
used and the double knot technique of stitching
is applied to get required shape and to
prevent the teething of the surface and
thread on the ball. The thread is coated
with seam sealant that prevents water and
mud to penetrate into the seams of the ball
or to damage the inner surface of ball.
This makes our sports balls available for
many games with optimum weight, shape and
movement control over it.
In all of our production operations, including
stitching of ball, there is no child labour,
forced labour or any other form of exploitation.
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Final
Inspection |
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The
sports balls goes through many inspection
points, during and after production, which
ensure top quality, smooth production and
on time delivery of balls to customers.
A final inspection is carried out before
packing and different checking techniques
are applied to control quality. |
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Packing |
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The
sports balls are packed systematically to
ensure safety and correct quantity of goods
in the packages. The requirements of each
customer are met for the packing, printing
and selection of packaging material. |
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Shipping |
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Now
sports balls are ready for shipment. Our
shipping and export department efficiently
arranges the movement of shipment and prepares
documents required for the shipment of goods.
There is systematic checklist of documents
and instructions, given in tech packs, against
each order which enable them to follow the
order requirement. The export department
keeps the customer up to date about all
the progress in this regard. |
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Customer
Satisfaction |
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Our
satisfied customers don’t give us
time to be idle and we are ever ready for
their next orders. |
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